Square D Smart Breaker Panel Control Manual (026 ... - icemeister.net

1640 Airport Road, Suite 104Kennesaw, GA 31044Phone: (770) 425-2724Fax: (770) 425-9319ALL RIGHTS RESERVED.The information contained in this manual has been carefully checked and is believed to be accurate. However, ComputerProcess Controls, Inc. assumes no responsibility for any inaccuracies that may be contained herein. In no event willComputer Process Controls, Inc. be liable for any direct, indirect, special, incidental, or consequential damages resultingfrom any defect or omission in this manual, even if advised of the possibility of such damages. In the interest of continuedproduct development, Computer Process Controls, Inc. reserves the right to make improvements to this manual, and theproducts described herein, at any time without notice or obligation.

Table of Contents1 OVERVIEW ................................................................................................................................................................... 11.1. THE SMART BREAKER SYSTEM.................................................................................................................................... 11.2. BREAKER NUMBERING ON THE SQUARE D MASTER AND SLAVE PANELS .................................................................. 11.2.1. Numbering Double and Triple Breakers............................................................................................................... 21.3. THE SQUARE D POWERLINK BREAKER PANEL ............................................................................................................ 31.3.1. Compatible Square D Panels................................................................................................................................ 31.3.2. Connection To Master Panel #0 (Master) ............................................................................................................ 31.3.3. Networking Square D Master Panel to Square D Expansion Rails...................................................................... 41.3.4. Expansion Panel Cable Maximum Length............................................................................................................ 41.3.5. Network Panel Addressing.................................................................................................................................... 52 E2 MODBUS DIRECT SUPPORT FOR SQUARE D BREAKER PANELS.......................................................... 62.1. NETWORK CONNECTION TO E2 .................................................................................................................................... 62.1.1. E2 Termination ..................................................................................................................................................... 72.2. E2 SETUP OF SQUARE D BREAKER PANELS................................................................................................................. 72.2.1. Set Up Network Ports............................................................................................................................................ 72.2.2. Add and Connect Square D Breaker Panels......................................................................................................... 72.3. SQUARE D APPLICATION SETUP IN E2: SINGLE BREAKER........................................................................................... 82.3.1. Adding Lighting Schedule Application ................................................................................................................. 82.3.2. Light Outputs and Proof Inputs Setup................................................................................................................... 82.3.2.1. Light Outputs Setup ............................................................................................................................................................ 92.3.2.2. Proof Inputs Setup .............................................................................................................................................................. 92.4. SQUARE D APPLICATION SETUP IN E2: MULTIPLE BREAKER GROUPING.................................................................. 102.4.1. Setting Light Outputs .......................................................................................................................................... 102.4.2. Proof Inputs Setup for Multiple Breaker Grouping............................................................................................ 113 SQUARE D SMART BREAKER GATEWAY BOARD ......................................................................................... 133.1. OVERVIEW .................................................................................................................................................................. 133.2. MOUNTING.................................................................................................................................................................. 133.2.1. Environmental Specifications ............................................................................................................................. 133.2.2. Square D Breaker Panel Mounting..................................................................................................................... 143.3. POWER WIRING .......................................................................................................................................................... 143.3.1. Square D Smart Breaker Gateway...................................................................................................................... 143.4. NETWORKING ............................................................................................................................................................. 143.4.1. Wiring the Square D Gateway to a Retail Solutions Site Controller (I/O Network) .......................................... 143.4.1.1. Wire Connection ............................................................................................................................................................... 153.4.1.2. Gateway Board I/O Network Addressing......................................................................................................................... 153.4.1.3. Setting the Baud Rate Dip Switches ................................................................................................................................. 153.4.1.4. Setting the RS485 I/O Termination Jumpers.................................................................................................................... 153.4.2. Gateway with Square D Panel............................................................................................................................ 163.4.2.1. MODBUS Network Termination...................................................................................................................................... 163.5. SITE CONTROLLER SOFTWARE SETUP - GATEWAY BOARD ....................................................................................... 163.5.1. REFLECS............................................................................................................................................................ 163.5.2. E2 and Einstein ................................................................................................................................................... 163.5.2.1. Board and Application Setup............................................................................................................................................ 163.5.2.2. Adding Lighting Schedule Applications........................................................................................................................... 173.5.2.3. Proof Inputs and Light Outputs Setup .............................................................................................................................. 173.6. SOFTWARE SETUP....................................................................................................................................................... 183.6.1. Smart Breaker Gateway (HHT) .......................................................................................................................... 183.6.1.1. HHT Screens..................................................................................................................................................................... 18Square D Smart Breaker Manual Table of Contents • 1

3.6.1.2. Configuration .................................................................................................................................................................... 193.6.1.3. Status................................................................................................................................................................................. 194 TROUBLESHOOTING............................................................................................................................................... 205 WORKSHEETS .......................................................................................................................................................... 215.1. BREAKER GROUP ASSIGNMENT.................................................................................................................................. 215.2. GATEWAY BOARD GROUP TO POINT NUMBER CALCULATION .................................................................................. 225.3. GATEWAY BOARD GROUP TO POINT NUMBER MAPPING .......................................................................................... 232 • Table of Contents 026-1711 Rev 2 06-29-09

1 Overview1.1. The Smart Breaker SystemThe Smart Breaker products are designed to allowthe Retail Solutions family of site controllers (RE-FLECS, Einstein, and E2) to command control panelsthat activate and deactivate lights. A breaker panelgenerally consists of a series of circuit breakers thatare flipped from OFF to ON and from ON to OFF bycommands sent from E2 through MODBUS or aSquare D Smart Breaker Gateway board. Support forproof checking on individual breakers is also supported.The Retail Solutions line of Smart Breaker productsinclude E2 direct MODBUS support or a Gatewayfor interfacing with Square D’s Powerlink G3breaker panels.1.2. Breaker Numbering on theSquare D Master and SlavePanelsFigure 1-1 shows the numbering for all breakerslots on the Square D Powerlink panels (24-breakerpanel shown), as they correspond to the breaker numbersmapped to groups in the HHT screen (see Section3.6.1.2., Configuration). For the master panel(Panel #0), the odd-numbered breakers are on thesame rail as the power supply, and the even-numberedbreakers are on the opposite rail. For slave panels, theodd-numbered breakers are on the same rail as the addressselector, and the even-numbered breakers are onthe opposite rail. In either case, all breakers are numberedin ascending order from the side closest thepower supply or address selector to the opposite endof the rail.The Smart Breaker System Overview • 1

1.2.1. Numbering Double and TripleBreakersIf double or triple breakers are being used in theSquare D Master and Slave panels, they will beplugged into more than one slot on the Square D Powerlinkpanel. However, double and triple breakersonly respond to ON/OFF commands sent to one of itsaddress slots.Double breakers occupy two slots in a Square DPanel. If a double breaker is on the left side of the paneluse its first slot for the control address, and if on theright side of the panel, use its second slot for the controladdress. For example, if a double breaker is on theleft in slots 3 and 5, the breaker address slot will be 3.If a double breaker is on the right in slots 4 and 6, thebreaker address slot will be 6.For triple breakers, use the center slot as the breakeraddress, as this will be the same for the left andright side of the panel. For both double and triplebreakers, all unused slots should be left unaddressed(i.e, assigned to Group #0 in the Gateway or unassignedwith E2 direct MODBUS control).POWERSUPPLYBreaker NumberingFor Square D Master PanelADDRESSSELECTORBreaker NumberingFor Square D Slave PanelRX TXTX RXRX TXTX RXCPUCPUCPUCPUFigure 1-1 - MODBUS Gateway to Square D Panel Wiring2 • Square D Smart Breaker Manual 026-1711 Rev 2 06-29-09

1.3. The Square D PowerlinkBreaker PanelFigure 1-2 - Square D Powerlink Breaker Panel (24-BreakerVersion Pictured)The Square D Powerlink breaker panels aredriven by an on-board power supply that handles staggeredactivation of breakers, proof checking and autoreset.Retail Solutions site controllers communicatewith the Square D Powerlink panels via its MODBUSnetwork connection. The Retail Solutions controllerdirectly commands the Square D Powerlink panel toturn its breakers to turn ON or OFF.A Powerlink panel consists of two rails of breakersconsisting of either 6, 9, 12, 15, 18, 21, or 24 breakerslots each, for a total of 12, 18, 24, 30, 36, 42, or 48breakers.1.3.1. Compatible Square D PanelsThe E2 Square D Smart Breaker system requiresone “master” panel to be equipped with a PowerlinkG3 power supply module (see Table 1-1 for part numbers).Square DPart #NF120PSG3NF240PSG3NF277PSG3DescriptionPowerlink G3 Power Supply,120VPowerlink G3 Power Supply,220/240VPowerlink G3 Power Supply,277VTable 1-1 - Square D Powerlink G3 Power SuppliesThe E2 Square D Smart Breaker system does NOTrequire, and cannot communicate with, Powerlink G3controllers such as the NF500G3, NF1000G3,NF2000G3, or NF3000G3. If one of these controllersis present on the master panel, remove it before installing.1.3.2. Connection To Master Panel #0(Master)Each Square D Smart breaker panel system has atleast one panel that is the “master” panel. The masterpanel has a power supply that provides power to turnthe breakers ON and OFF, both for itself and for expansionpanels, or “slave” panels. The master panel’sSquare D network address is always #0; however, it isreferred to in the Gateway’s interface as “Panel #1.”For E2 MODBUS direct connection, a total of upto eight (8) panels (one “master” panel and seven“slave” panels) can be addressed per E2, with the“master”panel always set up as the first panel.To network the master panel to the Square D Gateway,use two-connector shielded cable (Belden #8761or equivalent). Connect the Gateway’s MODBUSconnector (located in the top right corner of the board)to the pluggable connector on the bottom side of themaster panel’s power supply (see Figure 1-3).Square D GATEWAYRS485-0VRS485+HHTJACKBLACKSHIELDWHITEBELDEN #8761OR EQUIVALENTFigure 1-3 - MODBUS Gateway to Square D Panel WiringFor E2 MODBUS direct support the Gateway isnot used. Wire the MODBUS network directly to thepluggable connector on the bottom side of the masterpanel’s power supply (Figure 1-4):SHIELDBLACKWHITESquare DPanelPowerSupply(on Panel #0)NF120PSG3The Square D Powerlink Breaker Panel Overview • 3

Use Belden #27326 (4-conductor, 18 AWG Class1 cable) or equivalent to wire the expansion panels tothe MODBUS network. See Figure 1-5.To E2 and otherMODBUS DevicesBELDEN8761MODBUSNETWORKBELDEN #8761OR EQUIVALENTShieldRS485 (-)RS485 (+)+ABSquare D PanelPower Supply(on Master Panel #0)NF120PSG3NF120PSG3Square D PanelPower Supply(on MasterPanel #0)Figure 1-4 - E2 MODBUS to Square D Panel Wiring1.3.3. Networking Square D Master Panelto Square D Expansion RailsIn addition to Panel #0 mentioned in Section1.3.2., Connection To Master Panel #0 (Master), theSquare D Gateway can communicate with expansionpanels, or “slave panels.” Expansion panels must bewired in series with the master panel and the SquareD Gateway. The E2 MODBUS direct support cancommunicate with up to eight (8) Square D breakerpanels (one “master” panel and seven “slave” panels).Locate the address selector on each expansionpanel. The address selector has a four-terminal pluggableconnector next to the rotary addressing switch(Figure 1-5).To otherSquare DSlave PanelsTo Square DGateway or E2BLUEORANGEBLACKREDB A - +Address SelectorORANGEBLACKREDSquare DBreaker PanelSlave Panel(#1, 2,and/or 3)Figure 1-5 - MODBUS Square D Master Panel to ExpansionPanelBLUE1.3.4. Expansion Panel Cable MaximumLengthThe total amount of wire connecting the Powerlinkmaster panel to all slave panels is limited based on thetype of power supply being used and the nominal voltage.Table 1-2 lists the power supplies and their correspondingmaximum cable lengths.The maximum cable length does NOT include thecable connecting the master panel to the Gatewayboard or the E2 MODBUS network.4 • Square D Smart Breaker Manual 026-1711 Rev 2 06-29-09

Power SupplyPart #Nominal Voltage1.3.5. Network Panel AddressingMaxCableLengthNF120PSG3 120V 400 ft(122 m)NF240PSG3 220V 100 ft(30 m)240V400 ft(122 m)NF277PSG3 277V 400 ft(122 m)Table 1-2 - Square D Powerlink G3 Power SuppliesWhen more than one Square D Smart breaker panelis networked with the Square D Gateway or E2,each panel must be given a unique network ID on theMODBUS network. The panel with the power supply(the master panel) is always automatically addressedas Panel #0. Expansion panels must be addressed bysetting the rotary dial on the address selector. Eachexpansion panel should be numbered in sequence (#1,#2, and #3).Powerlink panels have no on-board terminationand must be terminated by placing a 150-ohm resistor,or by using the Retail Solutions terminal block(P/N 535-2711) between the B and A terminals on theMODBUS connector (Figure 1-6).B A - +Expansion Rail(End ofMODBUSNetwork)B A - +Figure 1-6 - Powerlink Panel MODBUS Termination(Expansion Rail Connector shown)The Square D Powerlink Breaker Panel Overview • 5

2 E2 MODBUS Direct Supportfor Square DBreaker Panels2.1. Network Connection to E2Connecting a Square D breaker panel to an E2 unitrequires the E2 to be version 2.71 or above. ContactRetail Solutions for upgrade information if the controlleris a version prior to 2.71.If you are using a REFLECS, Einstein, or E2 priorto version 2.71, a Gateway board is required to communicatewith the Square D Smart breaker panels.Refer to section Section 3, Square D Smart BreakerGateway Board for more information.E2 PIB COM PORT ASSOCIATIONSCOM4COM2E2 Enclosure (Right Side)E2 Modem/ExpansionCOM Card Mounted COM6Above PIBRS232COM3 Plug-InModemCardRS485COM1RS485 COM Card(2 Connectors) Serial DeviceRS232 PortPOWER INTERFACE BOARD(PIB)Serial DeviceRS485 COM Port(2 Connectors)E2MODBUS NETWORKTO OTHERSQUARE DPANELSSquare DBreakerPanelFigure 2-1 - Square D Panel MODBUS Connection LayoutFigure 2-2 - Location of E2 COM Ports - E2 PIB BoardAn E2 has up to three COM ports that can be assignedfor MODBUS communication (COM2, anRS485 port on the E2 power interface board, andCOM4 and COM6, which are optional ports requiringexpansion cards). COM ports can only be used for onefunction; in other words, if COM2 is set up as the I/Onetwork, you cannot connect MODBUS devices toCOM2. Ensure your E2 is equipped with an RS485COM Card (P/N 637-4890) and configured in E2General Services (, Serial tab) to enableCOM4 or an E2 Expansion COM Card (P/N 637-4871) to enable COM6.Connect the MODBUS network cable to the threeterminalconnector on the COM port you wish to assignas MODBUS. Wire RS485+ to the Square Dpower supply B terminal. RS485- to the Square Dpower supply A terminal, and the shield cable to theSquare D power supply minus (-) terminal.If other MODBUS devices are on the same networksegment as the Square D breaker panels, theyshould be wired prior to the first Square D breakerpanel. This is due to the MODBUS network wire typechange when going from a Square D “master” breakerpanel to a Square D “slave” breaker panel.6 • Square D Smart Breaker Manual 026-1711 Rev 2 06-29-09

CAUTION: When Square D Breaker Panelsare on the network, any MODBUS devices onthe network cannot have an address of 58. If aMODBUS device has an address of 58, it will cause theSquare D Breaker Panels to go offline.2.1.1. E2 TerminationIf the E2 will be the first device in the daisy-chain,set the port’s termination jumpers to the TERMI-NATED & BIASED position (all three jumpers UP);otherwise, set all jumpers DOWN if not the first device.2.2. E2 Setup of Square D BreakerPanels2.2.1. Set Up Network PortsBefore setting up a Square D breaker panel, theport on the E2 that has the MODBUS cable connectedmust be set up as a MODBUS port.1. Log in to the E2 with Level 4 access.2. Press followed by - GeneralController Info.3. Press + to open the Serial tab of theGeneral Controller Info setup screens:COM port connection field that will be used,and press - LOOK UP. From the listof network types, select MODBUS.5. Four fields will become visible underneaththe COM port connection field, which pertainto the way the device communicates:•Baud - Default setting is 19.2k. Leave thisfield at the default value.•Data Size - Leave this field at the defaultvalue (8).•Parity - Leave this field at the default value(None).•Stop Bits - Leave this field at the defaultvalue (1).6. Press to save changes and exit.2.2.2. Add and Connect Square D BreakerPanelsTo enable communications between E2 and theSquare D breaker panels, the devices must be addedand addressed in E2.1. Log in to the E2 with Level 4 access.2. Press - Connected I/OBoards and Controllers.Figure 2-4 - Connected I/O ScreenFigure 2-3 - Serial Communications Manager Screen4. This screen will have a “Connection” fieldfor all COM ports on the E2. Highlight the3. On the Connected I/O screen, in a box labeledThird Party Devices, enter the number ofSquare D Panels in the SqD Breaker Panelnumber field.4. Press to return to the Network SetupE2 Setup of Square D Breaker Panels E2 MODBUS Direct Support for Square D Breaker Panels • 7

menu, then select - Controller Setup(Figure 2-5).5. Locate the Square D breaker panels you addedto the network list (press and toscroll through the list). The default name fora Square D breaker panel begins with a twoletterdesignator of the model type (SD forSquare D). If desired, enter a new name foreach device in the Name field.•No Port - No port is set up in the E2 SerialConfiguration Manager to be a MODBUSport. Follow the instructions in Section2.2.1., Set Up Network Ports.Figure 2-6 - Online Status ScreenFigure 2-5 - Controller Setup ScreenEach Square D breaker panel is assigned a MOD-BUS address automatically when it is created. EachMODBUS panel has two addresses (one for the L railand one for the R rail). The addresses start at 232 (displayedunder the Node/Board# column inFigure 2-5) for the first panel (“master” panel) and234 for the second panel (“slave” panel #1), 236 forthe third panel (“slave” panel #2), up to a total of eightpanels. One “master” and seven “slave” panels.6. When finished, press to return to theNetwork Setup menu, then press - OnlineStatus (Figure 2-6). Locate the Square Dbreaker panels you set up, and look at eachdevice’s status in the Status field. You willsee one of the following messages:•Online - The Square D breaker panel iscommunicating normally.•Offline - The Square D breaker panel isnot communicating, has not been commissioned,is not functional, or is not poweredup. Verify the Square D breaker panel ispowered up, wired correctly, and has theproper network address, baud rate, and parity(see Section 4, Troubleshooting).2.3. Square D Application Setup inE2: Single Breaker2.3.1. Adding Lighting Schedule ApplicationFor each group of breakers to be controlled separately,set up a Lighting Schedule application fromthe Add New Application screen.Press the key to access the Main Menu,then:1. Add/Delete Application2. Add New ApplicationPress - LOOK UP to select LightingSchedule. Enter the number of desired applications inthe How Many? field.2.3.2. Light Outputs and Proof Inputs SetupOnce the Lighting Schedule applications havebeen added, set up the light output and proof input foreach Lighting application. (Proof input setup may beoptional.) The outputs of a Lighting Schedule cell8 • Square D Smart Breaker Manual 026-1711 Rev 2 06-29-09

control the breakers on the Square D breaker panels,and the proof inputs of the Lighting Schedule cell arethe Square D panel breaker status outputs.2.3.2.1. Light Outputs Setup1. Under the Outputs tab, change the LIGHTSOUTPUT format by pressing - EDITand then 1. Alternate I/O Formats to Controller:Application:Propertyfrom theBoard:Point format.2. For the Controller property, use -LOOK UP to select the Square D breakerpanel, for the Application property selectlighting panel, and for the Output property selectthe breaker input number(BREAKER_IN_X).Figure 2-8 - Enable Proofing on Setup TabIf using a single Square D breaker, associate theproof input (PROOF IN) with the Square D panel(Figure 2-9) and status of the breaker number fromthe More tab in the Lighting application:Figure 2-7 - Single Breaker Lighting Output Setup in E2Lighting2.3.2.2. Proof Inputs SetupTo enable proofing, set Enable Proofing to Yesfor each Lighting application under the Setup tab.Press or to access the LightingSchedule from the Home screen depending on whethera BX or CX E2 controller is being used.Figure 2-9 - Single Breaker Proof Input Setup in E2 Lighting1. Change the PROOF IN format by pressing - EDIT and then 1. Alternate I/OFormats to Controller:Application:Propertyfrom the Board:Point format.2. For the Controller property, use -LOOK UP to select the Square D breakerpanel, for the Application property selectlighting panel, and for the Output property selectthe breaker number (BREAKER_X).Square D Application Setup in E2: Single Breaker E2 MODBUS Direct Support for Square D Breaker Panels • 9

2.4. Square D Application Setup inE2: Multiple Breaker GroupingNOTE: A Group can contain one or morebreakers as defined by a user. Assigningmultiple breakers to a group allows an entiregroup of breakers to be turned on or off simultaneously,instead of each individual breakerbeing turned on or off separately.2.4.1. Setting Light Outputs1. To group multiple breakers to a single Lightingapplication, press - EDIT and select2. Set Multiple Outputs.Figure 2-11 - Multiple Output Setup View2. For the Controller property, press -LOOK UP to select the Square D breakerpanel, for the Application property selectlighting panel, and for the Property output selectthe breaker input number(BREAKER_IN_X). Repeat for each breakeryou wish to group to this Lighting application.Figure 2-10 - Set Multiple Breakers in E2 LightingThe Multiple Output Setup screen opens(Figure 2-11) where you can set up the Controller,Application, and Property Lighting outputs.10 • Square D Smart Breaker Manual 026-1711 Rev 2 06-29-09

2.4.2. Proof Inputs Setup for MultipleBreaker Grouping1. To enable proofing, set Enable Proofing toYes for each Lighting application under theSetup tab. Press or to accessthe Lighting Schedule from the Home screendepending on whether a BX or CX E2 controlleris being used.the General Setup and add a name that willassociate the proof input group to the Lightingapplication.3. Set the number of inputs to the number ofbreakers in the group.4. Under the Comb Ins tab, change the DIGINPUT1 format by pressing - EDITand then 1. Alternate I/O Formats to Controller:Application:Propertyfrom theBoard:Point format.5. For the Controller property, press -LOOK UP to select the Square D breakerpanel, for the Application property selectLighting Panel, and for the Inputs propertyselect the breaker numbers that are includedin the group.Figure 2-12 - Enable Proofing on Setup TabWhen grouping multiple breakers to a Lighting application,add a Digital Combiner application forproofing inputs:Figure 2-14 - Grouping Inputs in Digital Combiner6. Go back to the Lighting application under theMore tab and associate the Lighting group(Figure 2-15) with the Digital Combiner application:Figure 2-13 - Digital Combiner For Input Proof Grouping2. For grouping, set the combination method toAND under the Comb Method parameter inSquare D Application Setup in E2: Multiple Breaker GroupingPanels • 11E2 MODBUS Direct Support for Square D Breaker

Figure 2-15 - The Digital Combiner Used To Group InputsWhen using the Digital Combiner method above,the Proof Type must be set to ON Only.7. Under the More tab, change the PROOF INformat by pressing - EDIT and then 1.Alternate I/O Formats to Controller:Application:Propertyfrom the Board:Point format.8. For the Controller property, press -LOOK UP to select the E2 Name, for the Applicationproperty select the Digital Combinerthat you created, and for the Outputproperty select OUTPUT.12 • Square D Smart Breaker Manual 026-1711 Rev 2 06-29-09

3 Square D Smart BreakerGateway Board3.1. OverviewProof states for each breaker on the network arepassed to the Gateway Board, which are then combinedbased on the breaker groupings into a singledigital proof value for the entire group. This combinedproof state is fed back to the Retail Solutionssite controller via the board’s “virtual 16AI points”for purposes of displaying and alarming.954113E21021EINSTEINSMART BREAKERGATEWAY (SqD)MODBUS NETWORKTO OTHERSQUARE DPANELSSquare DBreakerPanelREFLECS1234568Hand-Held Terminal JackRS485 I/O NetworkRS485 Receiver Bus NetI/O Net Term JumpersLEGEND7891011Receiver Bus Term JumpersGeneral Status LEDFigure 3-1 - Square D Gateway LayoutThe Retail Solutions Square D Smart BreakerGateway Board serves as an interface between theRetail Solutions refrigeration and building controllers(REFLECS, Einstein, and E2) and the Square D Powerlinkbreaker panels. The Gateway Board connects tothe Retail Solutions controller via the RS485 I/O network(COM A & D on the REFLECS) and behavesidentically to one 16AI input boards and two 8ROoutput boards, meaning any of the controller’s lightingschedule applications may be used to controlbreakers on the Square D Powerlink panels by addressingthem as output points.The Gateway Board connects to up to four SquareD Powerlink panels via a MODBUS network connection.Within the Gateway Board’s software, breakerson the Powerlink panels can be grouped together sothat one virtual output point can be used to controlmultiple breakers. Up to 16 groups of breakers can becreated for up to four panels of 42 breakers each.76Alarm Status LEDDip SwitchPower ConnectorI/O Net Status LEDReceiver Bus Status LEDFigure 3-2 - Square D Panel Layout3.2. MountingThe Square D Gateway is typically mounted in thesame area as the Square D Breaker panels. The Gatewayis designed to fit into a standard 3” snap track(supplied with the board) or may be mounted in a panelor on stand-offs. Follow the dimensions inFigure 3-3 for panel mounting.Figure 3-3 - Gateway Board Mounting Dimensions3.2.1. Environmental SpecificationsThe Square D Gateway should be mounted in anenvironment with ambient temperature between-40°F and 150°F, with a non-condensing relative humiditybetween 5% and 95%.Overview Square D Smart Breaker Gateway Board • 13

3.2.2. Square D Breaker Panel MountingRefer to the documentation and diagrams suppliedwith your Square D breaker panel(s).3.3. Power Wiring3.3.1. Square D Smart Breaker GatewayInput VoltagePowerTable 3-1 - Gateway Power Requirements24VAC, Class 2, centertapped,50/60Hz5VAThe Square D Gateway requires 24VAC powerfrom a Class 2 center-tapped transformer.Retail Solutions supplies several sizes of centertappedtransformers for powering multiple 16AIs,8ROs, and other RS485 peripheral boards of the Einsteinand REFLECS systems.Refer to your controller’s user manual for informationon how to use the center-tapped transformerslisted in Table 3-2 to power multiple RS485 I/O devices.Figure 3-4 and Figure 3-5 show how to connectthe 56VA and 80VA transformers to the Square DGateway power connector.Three-Board Six-BoardP/N 640-0056 640-0080Power Rating 56 VA 80 VATable 3-2-Power Ratings for Retail Solutions TransformersFigure 3-4 - Pinout for the 56VA (640-0056) and 80VA (640-0080) TransformersFigure 3-5 - Power Wiring on Square D Gateway3.4. Networking3.4.1. Wiring the Square D Gateway to aRetail Solutions Site Controller (I/ONetwork)Each Einstein or REFLECS site controller thatwill command a Square D Smart breaker panel musthave a Square D Gateway installed on its RS485 I/ONetwork. For Einstein and E2 controllers, this meansthe Gateway will be installed on the I/O Network; forRMCC, BEC, BCU, and other REFLECS products,the Gateway will be installed on the COM A or COMD network.14 • Square D Smart Breaker Manual 026-1711 Rev 2 06-29-09

3.4.1.1. Wire ConnectionUsing shielded two-conductor network cable(Belden #8761 or equivalent), connect the RS485 I/ONetwork wire to the three-terminal connector on theGateway board as shown in Figure 3-6. For furtherinformation about how RS485 networks are configured,refer to your site controller’s user manual.boards. One board will use the address you enter, andthe second will be the next address number in the sequence.For example, setting this field to 4 will causethe two virtual 8RO boards to be numbered 4 and 5.3.4.1.3. Setting the Baud Rate Dip SwitchesDip switches 6 and 7 control the baud rate at whichthe Square D Gateway communicates with the sitecontroller on the RS485 Network. These switchesmust be set to the same baud rate setting as the Einsteinor REFLECS (usually 9600 baud).The MODBUS baud rate used by the Gatewayboard to communicate with the Square D panels isfixed at 19200 baud, since this is the only baud rateused by this device.Figure 3-6 - Connecting the Square D Gateway to the RS485Network3.4.1.2. Gateway Board I/O Network AddressingNOTE: The network dip switch on the Square DGateway board does not set the board number.Board numbering must be done with a Hand-Held Terminal.A Square D Gateway board behaves on the networkas if it were one (1) 16AI board and two (2) 8ROboards. Though the Gateway board has a set of dipswitches on it labeled “Network Switch,” this switchis not used to set the board numbering. Board numberingmust be done in the Gateway’s software using aHand-Held Terminal.With the Gateway board powered up, plug a HHTin the board’s HHT jack. When the screen titled “CPCSQUARED-GW” appears, press the down arrow keyonce to access the HHT screen used to set up networkaddressing.16AI ADDR: 18RO ADDR: 1Figure 3-7 - Dip Switch Setting for Square D Gateway BaudRate3.4.1.4. Setting the RS485 I/O Termination JumpersAs part of a site controller’s RS485 I/O (COM Aor COM D) Network, a Gateway must be terminatedif it is the end device of a daisy chain. Refer to the sitecontroller’s user manual for information about daisychain networks and how they are terminated.To terminate the Gateway, set the I/O NetworkJumpers to the RIGHT position as shown inFigure 3-8. To unterminate the Gateway, set thejumpers to the LEFT position.Press the RIGHT arrow key to make the cursor appear,and enter the address of the virtual 16AI boardthis Gateway will represent.Press the down arrow key to move the cursor to the8RO ADDR field. The number you enter in this fieldwill determine the address of the two virtual 8RONetworking Square D Smart Breaker Gateway Board • 15

Figure 3-8 - Square D Gateway RS485 I/O Network Termination3.4.2. Gateway with Square D PanelConnection between the Gateway and the SquareD Panel(s) is achieved through the MODBUS networkconnector at the top right of the Gateway boardand the network connectors on the Square D panels.3.4.2.1. MODBUS Network TerminationNOTERMINATIONTERMINATIONMODBUSTERM JUMPERSMODBUS NET(TO SQUARE DPANELS)3.5. Site Controller Software Setup- Gateway Board3.5.1. REFLECSEach group set up in the Gateway has its own virtual8RO and 16AI point command of the relay andproof feedback (respectively). Refer to your RE-FLECS controller’s manual for set up instructions.3.5.2. E2 and Einstein3.5.2.1. Board and Application SetupSet up the number of boards (one 16AI and two8ROs) on the I/O Network from the Connected I/Oscreen. Press the key to open the Main Menuand press:1. System Configuration2. Network Setup3. Connected I/O Boards and ControllersIf using an Einstein controller, from the Main Status/Homescreen, press (Actions), NetworkStatus/Setup, and then Connected I/O Boards &Controllers.Figure 3-9 - Square D Gateway MODBUS Network TerminationLike the RS485 I/O network, the two end deviceson the MODBUS network must be terminated. Typically,one of the end devices will be the Gatewayboard and the other a master or slave panel.Figure 3-9 shows the location of the MODBUStermination jumpers on the Gateway board. Non-Gateway E2 Software Setup (Direct Connection toE2).Figure 3-10 - Connected I/O Boards ScreenAdd one 16AI and two 8RO boards on this screen,and press to save and exit.16 • Square D Smart Breaker Manual 026-1711 Rev 2 06-29-09

3.5.2.2. Adding Lighting Schedule ApplicationsFor each group of breakers to be controlled separately,set up a Lighting Schedule application fromthe Add New Application screen.Press the key to access the Main Menu, then:If using an Einstein controller, from the Homescreen or Enhanced Lighting Status screen, press(Actions), (Setup), and choose the S1:Setuptab. (Note that the Proof tab is S8 and the Outputstab is S9).1. Add/Delete Application2. Add New Application3. - LOOK UP to select Lighting Schedule.Enter the number of desired applicationsin the How Many? field.If using an Einstein controller, from the Homescreen or Enhanced Lighting Status screen, press(Actions), (Control Appl Setup), and then (Add Control Application). Press (Look Up) toselect Enhanced Lighting. Press (Home) to returnto the Home screen.TRY THIS: When creating a name for yourLighting application, incorporate the application’scorresponding group number into thename. For example, PARKLIGHTS01 associates theparking lot breakers with Group 1.3.5.2.3. Proof Inputs and Light Outputs SetupOnce the Lighting Schedule applications havebeen added, set up the proof inputs and light outputsfor each Lighting application. The outputs of a LightingSchedule cell control the breakers on the SquareD panels, and the inputs are the combined proofs of allthe breakers that are part of the group being controlledby the application.Proof Inputs SetupSet up 16AI board inputs in Proof Setup. To enableproofing, set Enable Proofing to Yes foreach Lighting application by accessing the LightingControl Setup screen. From the Main Menu:1. Press (Lighting Sched) and select the aLighting application.2. (Setup) to go the Setup screen for thatLighting application.Figure 3-11 - Setup Lighting Control3. Under the C1:Setup tab, set EnableProofing to Yes. (C8:Proof tab becomesvisible once you cursor across the tabs.See Figure 3-12.)4. Press (Next Tab) or (Prev Tab) tocursor over to C8:Proof tab.Figure 3-12 - Lighting Proof Setup Screen5. Set Proof Type to ON Only. If the lightcircuit is read as open when it should normallybe closed, the 16AI board will send a “fail”input relay to the controller. The Gatewayproofs both ON and OFF so that the user canSite Controller Software Setup - Gateway Board Square D Smart Breaker Gateway Board • 17

select the desired proof type as ALL Values,ON Only, or OFF Only. If any breakerwithin a group fails the proof, the entiregroup will fail the proof.6. In the PROOF IN input, enter the virtualboard and point address of the proof input onthe gateway for the lighting group.7. Set Proof Delay to a minimum of twominutes. (0:02:00)8. Press (Next Tab) or (Prev Tab) tocursor over to C9: Outputs tab.Light Outputs SetupNOTE: If a breaker is assigned to a groupthat is not set up, a proof failure message willoccur.The Lighting Outputs Setup screen is where youwill set up the 8RO board and point numbers for eachgroup for all Lighting applications.Refer to Table 5-3 to associate the inputs and outputswith their corresponding group, board and pointnumbers.3.6. Software Setup3.6.1. Smart Breaker Gateway (HHT)Connect the HHT to the Gateway board via theHHT jack (refer to Figure 3-1). Use the HHT to assignindividual breakers to a particular group.HHT KeysF1F2CancelEnterFunctionHome screen keyQuick access to status informationLeft and right arrow keys pointto the desired field to be configuredUp and down arrow keys scrollthrough all breakers on panelscreensDeletes number you have chosenand changes it to zero, andcancels overrides on selectedfieldSaves changes (optional - usethe down arrow)-Toggles between override ONand OFF.Toggles between override ONand OFFTable 3-3 - 8RO Mapping3.6.1.1. HHT ScreensThe Home screen is the first screen that appears.Press F1 at any time to return to the Home screen:Figure 3-13 - Lighting Outputs Setup ScreenFor more information on setting up LightingSchedules, refer to section 9.7 Lighting Schedules inthe E2 RX Refrigeration and BX HVAC I&O Manual.CPC - SQUARED GW810-3721VER: 1.10B05(PRESS )Figure 3-14 - Home ScreenPress the down arrow key to move to the StartingBoard Addresses screen.18 • Square D Smart Breaker Manual 026-1711 Rev 2 06-29-09

Figure 3-15 - Starting Board Addresses ScreenThe Gateway emulates one 16AI and two 8ROs onthe I/O Network. Set the 16AI and 8RO addresses usingthe left or right arrow keys to activate the correspondingfields, and number the boards accordingly.The 16AI address should be the first unused boardnumber with a valid range of 1-16. The 8RO shouldbe the next available 8RO I/O Network address witha valid range of 1-31.For example, if you currently have three 16AIsand six 8ROs, set the 16AI address to 4 and the 8ROaddress to 7. If you add a 16AI and 8RO after theGateway, set their addresses as follows: 16AI to 5 andthe 8RO to 9.Next, arrow down to the Option screen:Figure 3-16 - Option Screen16AI ADDR: 18RO ADDR: 1OPTION: 31= STATUS2= DIAGS3= CONFIGPANEL 1BRK 1 GRP 1BRK 2 GRP 1BRK 3 GRP 1Figure 3-17 - Panel 1 Breakers to Group ScreenFrom this screen you can begin assigning breakerson panels 1 through 4 to breaker groups. Refer toFigure 1-1 for a diagram of the Square D Powerlinkpanel and the numbered breaker addresses.NOTE: The address numbers of the Square Dpanels do not correspond to what the HHTGateway interface calls “panel numbers.” Themaster panel is referred to in the HHT interface as“Panel #1,” even though its network address is zero.Also, the panels addressed #1, #2, and #3 are referredto in the interface as Panel #2, Panel #3, and Panel #4respectively.Use the left and right arrow keys to configure thebreaker’s group number. Change the group number tothe group you want to associate the breaker with (amaximum number of 16).A group number field becomes active when yousee the arrow appear next to the number. Use thedown arrow key to scroll through all 42 breakers oneach of the four panels and set the group numbers asyou scroll through the breakers.Option No.Function1 Status information that can beoverridden. (An asterisk “*” signifiesa proof failure)2 Diagnostics for troubleshooting3 Configuration settingsTable 3-4 - Option Choices Chart3.6.1.2. ConfigurationUse the left or right arrows to activate the OP-TION: field and choose the desired option number.(Select 3 to start configuring each Panel’s breakers togroups.) Press the down arrow to move to the nextscreen.NOTE: If a breaker is assigned to a groupthat is not set up, a proof failure message willoccur.3.6.1.3. StatusFrom the Option screen, select 1 for Status. TheStatus screen shows the status of the 16 groups andshows the ON or OFF state of each group and anyproof failures (a proof failure is indicated by “*” afterthe ON or OFF state). Press the down arrow key toscroll through the groups. After the groups are displayed,continue pressing the down arrow key to seethe ON or OFF state and any proof failures of each ofthe 42 breakers and all panels.If a group is not assigned or set to zero, a “-” willappear as the breaker status.Software Setup Square D Smart Breaker Gateway Board • 19

1. Check Wiring - Verify the Square D breakerpanel is properly connected to the MODBUScable. Verify the network polarity is correct(MODBUS 485+ to Square D terminal B,MODBUS 485- to Square D terminal A,MODBUS shield to terminal - ) and there areno loose wires. If none of the Square D breakerpanels are online, check wiring connectionson the E2. Check the cable jackets tomake sure all network cable is Belden #8761or equivalent.2. Verify MODBUS Port Setup - Press +on the E2 front panel. Verify COM2, COM4,or COM6 is set up as a MODBUS port. If so,verify that the MODBUS cable is connectedto the proper connectors. Verify the COMport fields (Figure 2-2) are properly set forECT MODBUS (19.2k baud, data size=8bits, Parity=NONE, stop bits=1).3. Check Square D Breaker Panel Slave AddressSelector Numbering - Verify that theslave selector matches the “address selector”parameter under the Devices tab in E2.4. Verify Slave Bus Interconnect Cable - Forpanels with both L and R rails, verify theslave bus interconnect cable is connected toone end to the L and the other to the R. Bothends of the cable are connected to both the Land R rails.5. Verify 4 Conductor Wiring Between TheMaster Panel And Slave Panels - Verify theB A - + polarity is consistent from master toslave panels, and the max length does not exceed400 ft (100 feet for 220V panels).OPTION: 11= STATUS2= DIAGS3= CONFIG6. Check Network Termination - The two deviceson either end of the MODBUS networkshould be terminated, with all other devicesin the daisy chain unterminated. Check jumpersettings for all devices on the network.Figure 3-18 - Option Screen4 TroubleshootingTroubleshooting Square D BreakerPanels and the MODBUS NetworkProblem: Square D Breaker Panel Offline20 • Square D Smart Breaker Manual 026-1711 Rev 2 06-29-09

5 Worksheets5.1. Breaker Group AssignmentUse the workspace below to assign breakers to groups. If using the Gateway board, refer to Table 5-3 forgroup number board and point assignment.Panel 1 Breakers Panel 2 Breakers Panel 3 Breakers Panel 4 BreakersGroup# Group# Group# Group# Group# Group# Group# Group#1 ___ 22 ___ 1 ___ 22 ___ 1 ___ 22 ___ 1 ___ 22 ___2 ___ 23 ___ 2 ___ 23 ___ 2 ___ 23 ___ 2 ___ 23 ___3 ___ 24 ___ 3 ___ 24 ___ 3 ___ 24 ___ 3 ___ 24 ___4 ___ 25 ___ 4 ___ 25 ___ 4 ___ 25 ___ 4 ___ 25 ___5 ___ 26 ___ 5 ___ 26 ___ 5 ___ 26 ___ 5 ___ 26 ___6 ___ 27 ___ 6 ___ 27 ___ 6 ___ 27 ___ 6 ___ 27 ___7 ___ 28 ___ 7 ___ 28 ___ 7 ___ 28 ___ 7 ___ 28 ___8 ___ 29 ___ 8 ___ 29 ___ 8 ___ 29 ___ 8 ___ 29 ___9 ___ 30 ___ 9 ___ 30 ___ 9 ___ 30 ___ 9 ___ 30 ___10 ___ 31 ___ 10 ___ 31 ___ 10 ___ 31 ___ 10 ___ 31 ___11 ___ 32 ___ 11 ___ 32 ___ 11 ___ 32 ___ 11 ___ 32 ___12 ___ 33 ___ 12 ___ 33 ___ 12 ___ 33 ___ 12 ___ 33 ___13 ___ 34 ___ 13 ___ 34 ___ 13 ___ 34 ___ 13 ___ 34 ___14 ___ 35 ___ 14 ___ 35 ___ 14 ___ 35 ___ 14 ___ 35 ___15 ___ 36 ___ 15 ___ 36 ___ 15 ___ 36 ___ 15 ___ 36 ___16 ___ 37 ___ 16 ___ 37 ___ 16 ___ 37 ___ 16 ___ 37 ___17 ___ 38 ___ 17 ___ 38 ___ 17 ___ 38 ___ 17 ___ 38 ___18 ___ 39 ___ 18 ___ 39 ___ 18 ___ 39 ___ 18 ___ 39 ___19 ___ 40 ___ 19 ___ 40 ___ 19 ___ 40 ___ 19 ___ 40 ___20 ___ 41 ___ 20 ___ 41 ___ 20 ___ 41 ___ 20 ___ 41 ___21 ___ 42 ___ 21 ___ 42 ___ 21 ___ 42 ___ 21 ___ 42 ___Table 5-1 - Assign Breakers to Group NumbersBreaker Group Assignment Worksheets • 21

5.2. Gateway Board Group to Point Number CalculationThis worksheet is for mapping breaker group numbers to board and points (Bd:Pt). Up to a maximum of 16groups can be set up, but an unlimited amount of breakers can be assigned to any given group.Table 5-2 shows the correlation between the group numbers and the virtual 16AI and 8RO points of the Gateway.Y represents the 16AI address and X represents the 8RO address of the Gateway configured in Section3.6.1.1., HHT Screens as shown in Figure 3-15.LightScheduleGroupProofIn(Bd)16AIAddrProofIn(Pt)16AIPointsLightsOutput(Bd)8ROAddr1 Y 1 X 12 Y 2 X 23 Y 3 X 34 Y 4 X 45 Y 5 X 56 Y 6 X 67 Y 7 X 78 Y 8 X 89 Y 9 X+1 110 Y 10 X+1 211 Y 11 X+1 312 Y 12 X+1 413 Y 13 X+1 514 Y 14 X+1 615 Y 15 X+1 716 Y 16 X+1 8Table 5-2 - Mapping Group Numbers to Point NumbersLightsOutput(Pt)8ROPoints

5.3. Gateway Board Group to Point Number Mapping16AI Address = ____ Fill in the Gateway 16AI board address that you set with the HHT.8RO Address = ____Fill in the Gateway 8RO board address that you set with the HHT for Groups 1-8. For Groups9-16, use the next consecutive 8RO board address (add 1).LightScheduleGroupProofIn(Bd)16AIAddrProofIn(Pt)16AIPointsLightsOutput(Bd)8ROAddr1 1 12 2 23 3 34 4 45 5 56 6 67 7 78 8 89 9 110 10 211 11 312 12 413 13 514 14 615 15 716 16 8Table 5-3 - Mapping Group Numbers to Point NumbersLightsOutput(Pt)8ROPointsGroup NameGateway Board Group to Point Number Mapping Worksheets • 23